WO2004041116A2

WO2004041116A2 - Appliance with bilayer base

Info

Publication number: WO2004041116A2
Application number: PCT/US2003/027838
Authority: WO
Inventors: Andrew C. Kesling
Original assignee: Tp Orthodontics, Inc.
Priority date: 2002-11-01
Filing date: 2003-08-29
Publication date: 2004-05-21
Also published as: CN1937968B; WO2004041116A3; EP1562511A2; EP1562511B1; WO2004041116B1; ATE464854T1; CN1937968A; EP1562511A4; MXPA05004687A; AU2003265937A8; US6746242B1; USRE45743E1; ES2340272T3; JP4503440B2; DE60332263D1; JP2006504484A; AU2003265937A1

Abstract

A bilayer base (16, 32) for attaching appliances (10, 30) selected from the group consisting of a component of a dental appliance, an orthodontic appliance, or an orthopedic appliance to a bony part of the human body wherein the appliance part to be attached to the bony part of the body may be made of metal, ceramic, or plastic. The base permits the appliance to be ready for mounting and includes a cured layer (22, 34) of polymer resin mounted on the appliance and an uncured layer (24, 36) of substantially the same polymer resin over the cured layer which when cured becomes integral with the cured layer in attaching the appliance to a bony part of the body.

Description

APPLIANCE WITH BILAYER BASE

Technical Field

This invention relates in general to a ready appliance for immediate

attachment to a bony part of the human anatomy, and more particularly to an

adhesive base on the appliance having a cured layer of plastic material attached

to the appliance and an uncured layer of substantially the same material to be

cured at the time of mounting the appliance on a bony part of the human

anatomy.

BACKGROUND ART

Heretofore, direct bonding techniques for mounting brackets on teeth

have long been known, as disclosed in U.S. Patent 3,250,002, and it has been

known to provide prepasted orthodontic appliances (appliances having uncured

adhesive on the mounting side) to orthodontists for immediate mounting or

direct bonding onto teeth, without requiring the orthodontist to apply adhesive,

as disclosed in U.S. Patents 4,204,325; 4,978,007; 5,183,403 and 5,697,780.

Such prepasted orthodontic appliances include a body provided with an uncured layer of chemically curable or light-curable adhesive on the mounting

side which when cured attaches and secures the appliance to a tooth. Light-

curable adhesives are well known, such as disclosed in U.S. Patents 3,629,187

and 4,978,007. It is also well known to provide orthodontic appliances

including metal mesh bases to which an uncured layer of adhesive is applied

prior to being sold to an orthodontist.

An appliance with a cured polymer resin base has also been known for a

ceramic orthodontic bracket, as disclosed in U.S. Patents 5,098,288 and

5,263,859, wherein the base facilitates removal of the bracket from the tooth

without damaging the tooth. Such brackets have been sold by TP

Orthodontics, Inc. of LaPorte, Indiana, under the trademark Mxi. Plastic

brackets have also been known to be mounted with a light-curable polymer

resin, as in U.S. Patent 3,745,653.

It has also been known to provide orthodontic appliances having a cured

layer of paste and an uncured layer of paste with embedded particles to prevent

the uncured layer from being tacky, as disclosed in U.S. Patent 5,810,584.

DISCLOSURE OF THE INVENTION

The present invention is in providing a bilayer base for orthodontic

appliances or orthopedic prosthetics to be ready for immediate mounting on the

bony part of the human anatomy. The bilayer base includes a layer of cured

plastic material of a suitable polymer resin and which is molded onto and

permanently mounted on the appliance. A further layer of uncured polymer resin is applied to the cured layer and the appliance is then suitably packaged

and shipped to an orthodontic or orthopedic customer, who mounts the

appliance onto a bony part of the human anatomy, cures the uncured layer of

polymer resin, thereby defining an integral base that is cured onto the bony

part of the human anatomy.

The polymer resin of the cured layer, as well as the uncured layer, is of

substantially the same type and from the same family of resins and may be

cured by light energy, chemical energy, or heat energy. Preferably the polymer

resin is of a type that is light-curable, and with respect to this version, the cured

layer serves to wick or transmit the curing light energy to the entire uncured

layer, thereby enhancing the curing step to produce a strong bond. The cured

layer of resin is of any suitable polymer resin such as an acrylic, an epoxy or an

acrylic-based epoxy. For example, an orthodontic appliance, such as a bracket,

that may be of metal, ceramic, or plastic would first be provided with a layer of

the polymer resin which would be cured to define the first layer of a bilayer

base. Secondly, an uncured layer of substantially the same polymer resin would

be applied to the cured layer and the appliance with this bilayer base would be

suitably packaged and shipped to an orthodontic customer, who would mount

the bracket on a tooth, after suitably preparing the tooth, and thereafter cure or

polymerize the uncured layer of resin to effect attachment of the bracket to a

tooth.

Similarly, the bilayer base can be used for orthopedic prosthesis

assemblies such as where a hip, knee or other joint replacement is satisfied with the implantation of an orthopedic prosthesis of the type shown in U.S. Patent

6,432, 141. One part of the prosthesis would normally include a stem that

would be inserted into a canal of a bone. According to the present invention,

the stem would have the bilayer base of a suitable polymer resin and at the time

of mounting on a bone the uncured layer of adhesive would be activated by

light, chemical, or heat energy to attach the part to a bone of the human

anatomy. As above explained with respect to the bilayer base on an

orthodontic appliance having a light-cure resin, the cured layer serves as a light

bar or conduit to allow the light energy to blanket the uncured layer.

Accordingly, the ready-made bilayer base of the present invention could

be used in the dental or orthopedic field for attaching appliances to the bony

structure of the body.

It is therefore an object of the present invention to provide a new and

improved bilayer base for appliances to be mounted on bony parts of the body

including teeth and bones.

Another object of the present invention is to provide for an appliance

with a bilayer base to be mounted on a bony part of the body wherein because

of the materials of the base a greatly enhanced bonding structure will be

established between the appliance and the bony part of the body.

A further object of the present invention is to provide a ready appliance

for the convenience of the user such as an orthodontic bracket having a bilayer

base with a cured layer and an uncured layer of polymer resin that not only enhances the bonding strength of the base to a bony part of the body but also

facilitates the removal of the base at a time when the bracket is to be removed.

A still further object of the present invention is to provide an orthodontic

appliance, in the form of a bracket, tube or button with a ready bilayer base

that facilitates the handling of the appliance at a time when used by an

orthodontist to mount on a tooth wherein the bilayer base includes a cured

layer of polymer resin on the appliance body and an uncured layer of polymer

resin over the cured layer and from the same family of resins as the cured layer,

wherein the uncured layer would be cured at the time of mounting the

appliance on a tooth and form an integral base for the appliance.

A further object of the present invention is to provide a bilayer base

including a transparent or translucent cured layer and an uncured layer of

transparent or translucent light-curable resin for an orthodontic or orthopedic

appliance, wherein the cured layer functions to wick or transmit the curing light

energy over the entire layer of uncured resin to produce curing of the entire

uncured layer and a better bond between the appliance and the surfaces on

which the appliance is to be attached.

Other objects, features and advantages of the invention will be apparent

from the following detailed disclosure, taken in conjunction with the

accompanying sheets of drawings, wherein like reference numerals refer to like

parts. DESCRIPTION OF THE DRAWINGS

Fig. 1 is a perspective view of an orthodontic bracket mounted on a tooth

with the bilayer base of the present invention;

Fig. 2 is a vertical cross-sectional view taken through an orthodontic

bracket like that in Fig. 1 wherein the first layer of the bilayer base has been

applied to the bracket body and cured;

Fig. 3 is a view similar to Fig. 2 but also showing the layer of uncured

polymer resin in place over the cured layer to define a bracket ready for

mounting on a tooth;

Fig. 4 is a vertical sectional view taken substantially along line 4-4 of Fig.

1 and illustrating the second layer of the base cured and that it becomes

integral with the initially cured layer to provide the complete base for the

appliance according to the present invention;

Fig. 5 is a cross-sectional view of an orthopedic prosthesis having the

initial cured layer of the bilayer base according tot he present invention;

Fig. 6 is a view similar to Fig. 5 and further showing the layer of uncured

polymer resin over the cured layer of polymer resin and thereby depicting the

appliance as it would be delivered to a user desiring to install the appliance on

the bone of a person; and

Fig. 7 is a sectional view taken through the appliance of Figs. 5 and 6 and

a bone to which the appliance is attached and illustrating the cured and

uncured layer as being integral and attached to the bone of a person. DESCRIPTION OF THE INVENTION

Referring now to the drawings, and particularly to Figs. 1 to 4, an

orthodontic bracket 10 is shown in mounted position on a tooth 11 in Figs. 1

and 4 to illustrate the invention. It will be appreciated that the bracket 10

includes a bracket body 14 and a base 16.

While the bracket body 14 illustrates a bracket of a type that is sold by

TP Orthodontics, Inc. of LaPorte, Indiana, it will be appreciated with respect to

the invention the bracket body may be of any suitable type and of any suitable

material. Moreover, the invention, being directed primarily to the base, can be

used on any appliance that would be mounted on a tooth, including a bracket, a

molar tube, or a lingual button, an implantable stem for a tooth implant, or

other appliance desired to be bonded to a tooth or the jaw for purposes of

dentally or orthodontically treating a patient. Thus, the appliance body 14 may

be of any type that would be useful in treating the dentition of a patient,

orthodontically or otherwise, where it would be desired to adhesively bond an

appliance in a desired place. Moreover, as will be discussed further below, the

base of the invention can be used for orthopedic appliances to mount a part of a

prosthesis on a bone of a person.

The body of the appliance, and in this case the bracket 14, may be made

of any suitable material for an orthodontic appliance, such as metal like

stainless steel, ceramic, or plastic. Similarly, if the appliance body is a buccal

tube, it can be made of any of these materials. As seen particularly in Figs. 2, 3 and 4, the bracket body 14 includes an archwire receiving side 18 and a base

receiving side 20. The base 16 is mounted onto the base receiving side 20.

The bracket is made by suitably preparing the surface of the bracket

body and then molding or otherwise applying a first layer 22 of a polymer resin

to the bracket and then curing that layer. Preferably, the layer includes edges

that overlap the edges of the bracket body as illustrated in order to provide the

best possible bonding or connection between the layer 22 and the bracket body

and also enhance the transmission of light during the curing of the second layer.

This step of the manufacture is illustrated in Fig. 2 where only the cured layer

22 is shown on the mounting side of the bracket.

Next, a second layer 24 of a polymer resin is suitably applied over the

first layer 22. This layer is maintained in an uncured state, and therefore the

appliance is provided to the orthodontic customer so that the orthodontist,

after preparing the tooth on which the bracket is to be mounted, can merely

apply the bracket with the bilayer base onto the tooth and then cure the

second layer 24 accomplishing the mounting or attachment of the bracket to

the tooth. Once the second layer is cured, it will merge and be essentially

integral with the first layer as the base of the bracket, as shown in Fig. 4, and

thereby provide the complete bonding connection between the bracket and the

surface of the tooth 11.

The polymer resin of the first layer 20 may be acrylic, epoxy or acrylic-

based epoxy resin, or any other suitable resin. Further, the resin may be of a

type that is light-curable, chemically curable, or heat-curable. Preferably, the resin is of a type that is light-curable. Moreover, the second layer 24 is of a

polymer resin in the same polymer resin family as the polymer resin of the first

layer 22. Preferably, the polymer resins are substantially identical to one

another, and an acrylic-based epoxy that is light-curable. As long as the resins

of each layer are from the same family, which enhances the bonding between

the layers, the curing/polymerization process of each need not be the same. For

example, the cured layer may be heat cured, while the uncured layer may be

light-curable.

It will be appreciated that the bracket with the bilayer base having a

cured layer of polymer resin and an uncured layer of polymer resin will be

shipped and transported to a customer in such a way as to protect the integrity

of the uncured layer and also prevent it from curing during the time it is in

transport. One method of transporting the appliance with the bilayer base is to

flush it with nitrogen to preserve the uncured state of the adhesive resin and

then hermetically seal it in a package to prevent light from activating the curing

cycle of the uncured adhesive. Where the base is of a light-curable resin, the

transparent or translucent cured layer further functions as a light conduit for

the curing light energy to allow the energy to fully activate the uncured layer of

resin and fully cure the layer to fully bond the appliance to the mounting

surface. Thus, the light energy wicks or moves easily along the cured layer.

One of the layers may be transparent, while the other layer is translucent.

Preferably, the cured layer is transparent to optimize the transmission of the

curing light energy. Thus, the bracket of the invention, having a bilayer base, is ready for the

orthodontist to mount on a tooth and thereafter to direct a curing light at the

uncured layer of the polymer resin to cure the layer and firmly attach the

bracket to a tooth.

The bilayer base of the invention is illustrated as being applicable to an

orthopedic prosthesis in Figs. 5 to 7, wherein Fig. 6 shows an elongated stem 30

over which the bilayer base 32 has been formed to define a prosthetic part

ready to be used by the orthopedic customer for attachment to a bone following

light-curing of the uncured layer of the base. The base 32 includes a cured layer

34 of a polymer resin over which an uncured layer 36 of substantially the same,

if not the same, polymer resin is provided to complete the base.

Fig. 5 shows the orthopedic stem 30 with only the cured layer 34 applied

to the stem in the manufacture of the bilayer base. Thereafter, the uncured

layer 36 is added before shipping the stem to an orthopedic customer, as shown

in Fig. 6.

It will be appreciated that the orthopedic prosthesis stem 30 could be

made of any suitable material, such as metal, ceramic, or plastic, and be formed

for use in any articulated part of the human anatomy. The particular appliance

stem 30 shown is intended to be used for a hip replacement procedure to

replace a part of a diseased femur 38. A canal 40 is suitably formed, such as by

drilling, in the end of the femur and into which the end of the prosthetic device

is inserted. It will be appreciated that with respect to artificial knee replacements, as

well as hip replacements, cemented and uncemented prostheses may be used.

The present invention relates only to the use of a cemented prosthesis, and as

above mentioned, the stem 30 may be made of any suitable material although it

is usually made of metal. Again, the appliance with the bilayer base as shown

in Fig. 6, wherein the outer layer 36 is provided in an uncured state before

being provided to a customer like the above described orthodontic appliance.

Also, like an orthodontic appliance with the base of the invention, the

prosthesis would be flushed with nitrogen and then hermetically sealed in a

container that would not allow any light transmission to prevent curing of the

light-curable polymer resin layer of the bilayer base when shipping the

prosthesis to an orthopedic customer.

It will be appreciated that the polymer materials of the bilayer base may

be of the same type as above identified with respect to the orthodontic

appliance. And where the polymer material of the uncured layer is light-

curable, and the cured layer is transparent or translucent, the cured layer

further functions to wick or transmit the light energy of a curing light to the

entire uncured layer.

Fig. 7 illustrates the orthopedic part 30 having its bilayer base in place in

a canal of a femur and the uncured layer, wherein the cured and uncured layers

of the base integrally join together during the time the uncured layer attaches to

the bone of the femur and connects the part to the femur. It will be appreciated that the illustrations of an orthodontic bracket and

a part of a prosthetic artificial joint are merely illustrative of the scope and use

of the bilayer base according to the invention as it could be used in connection

with any artificial part that is to be secured to a bone or tooth of the body.

It will be understood that modifications and variations may be effected

without departing from the scope of the novel concepts of the present

invention, but it is understood that this application is to be limited only by the

scope of the appended claims.

Claims

APPLIANCE WITH BILAYER BASEClaimsThe invention is hereby claimed as follows:

1. The combination of an orthodontic appliance ( 10) and a

laminated base (16) for ready mounting of the appliance on a tooth (11), said

base comprising:

a first layer (22) of cured polymer resin, and

a second layer (24) of uncured polymer resin of substantially the same

family as the first layer.

2. The combination of Claim 1, wherein said appliance is a bracket

or a tube.

3. The combination of Claim 1 , wherein said appliance is of metal,

ceramic, or plastic material.

4. The combination of Claim 1 , wherein said polymer resin is light,

chemical, or heat-curable.

5. The combination of Claim 1 , wherein said polymer resin is from

the group of acrylic, epoxy, or acrylic-based epoxy resins.

6. The combination of Claim 1 , wherein said polymer resin is

transparent or translucent.

7. The combination of an appliance (10, 30) and a base (16, 32)

thereon for ready mounting of the appliance on a bone (11, 38) of a person,

said base comprising,

a first layer of cured polymer resin (22, 34), and

a second layer of uncured polymer resin (24, 36) of substantially the

same family as the resin of the first layer that engages the bone and is cured

thereafter to be integral with the first layer and attach the appliance to the

bone.

8. The combination of Claim 7, wherein the appliance is an

orthopedic appliance (30) of metal, ceramic or plastic material, and the polymer

resin is from the group of light, chemical, or heat-curable resins.

9. A bilayer base (16, 32) for an appliance (10, 30) mountable on

bones and/or teeth of the human anatomy, said base comprising:

a first layer (22, 34) of a polymer resin in a cured state, and

a second layer (24, 36) of a polymer resin in an uncured state superposed

over the first layer,

said polymer resins of both layers being of substantially the same type,

whereby application of the appliance to a selected part of the human anatomy

and curing of said second layer causes said second layer to be integral with the

first layer, and firmly mounts the appliance to said selected part.

10. In an appliance selected from the group consisting of a component

of a dental appliance, an orthodontic appliance, or an orthopedic appliance such

as a joint prosthesis, wherein the appliance includes means thereon for

attaching at least part of the appliance to a bony part of the human body, and

which component includes a part made of metal, ceramic or plastic and said

attaching means is a base secured to the part,

the improvement being in the attaching means (16, 32) which comprises

a cured layer (22, 34) of polymer resin mounted directly on said part, and an

uncured layer (24, 36) of polymer resin over at least a part of the cured layer

which when cured becomes integral with the cured layer and attaches the part

to said bony part.

11. In an appliance according to Claim 10, wherein the polymer resin

of the uncured layer is of the same family of resins as the polymer resin of the

cured layer.

12. In an appliance according to Claim 10, wherein the polymer resin

of said layers is of a type that is curable by heat energy, chemical energy, or

light energy.

13. In an appliance according to Claim 10, wherein the polymer resin

is transparent or translucent.

14. In an appliance according to Claim 10, wherein the polymer resin

of the uncured layer is light-curable and the polymer resin of the cured layer is

transparent or translucent, whereby the cured layer functions to wick or

transmit light energy to the entire uncured layer and produce complete curing

of the uncured layer.